Insulated HVAC transition box and assembly for insulating

ABSTRACT

An insulated HVAC duct component such as a transition box includes a first insulation layer and a second, different insulation layer. The transition box includes at least four sidewalls and one of a top and a back wall, the transition box further including a first access port and a second access port, the first access port having a different cross section than the second access port, one of the access ports being spaced from a nearest sidewall by less than 2 inches. The first insulation layer is located along an inside surface of the box. The second different insulation layer overlies the first insulation layer, the second different insulation layer having an air impervious surface, wherein the combined thickness of the first insulation layer and the second different insulation layer is less than 2 inches.

CROSS-REFERENCE TO RELATED APPLICATIONS

None.

STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT

None.

REFERENCE TO A “SEQUENCE LISTING”

None.

BACKGROUND OF THE INVENTION Field of the Invention

The present disclosure relates to insulated HVAC duct components andmore specifically to after market pre-formed insulating components andinsulated HVAC transition boxes having a first insulation layer and asecond, different insulation layer.

Description of the Related Art

The insulation of ducts, such as HVAC ducts, provides a number ofbenefits including energy efficiency and noise reduction. Typically,mineral wool insulation is placed inside or outside duct components toprovide such benefits. Recent changes in building codes and regulations,however, now require that transition boxes, including register boxes,have increased R values. To increase the R value of and resist thermaltransfer in HVAC systems, an increased amount of mineral wool insulationcan be used. However, while the thickness of the insulation increasesthe R value, the increased thickness does not fit within a standard sizetransition box. For example, a register box typically includes a spaceof two inches or less between a back wall and a collar and between thesidewalls and the lip of the register box. Although the insulationmaterial can be compressed to fit inside the transition box, thisreduces the R value and does not provide sufficient insulation. Whilethe size of the register box can be increased, this is costly, notaesthetically pleasing, and reduces available operable locations for thebox.

What is needed then is a transition box which can be manufactured withexisting technology and allow installation in existing formats, whereinthe register box has increased resistance to thermal transfer. The needalso exists for a register box that can be constructed in a relativelyreduced size, thereby allowing installation into previously unattainablespaces, while meeting industry or municipal standards for resistance tothermal transfer. A need also exists for an insulating component thatcan be transported (shipped) in a first configuration and formed into asecond operable configuration without requiring any assembly by theinstaller.

BRIEF SUMMARY OF THE INVENTION

The insulated HVAC duct component of the present system provides forincreased resistance to thermal flow and can be constructed with reducedinsulation thickness allowing insulation in smaller formats orinstallation of higher R value transition boxes in previouslyunavailable locations while meeting increasing municipal or industrystandards for resistance to thermal flow.

In one configuration, the insulated HVAC duct component comprises aregister box having two sets of opposing sidewalls, a bottom wall, and atop wall having a rectangular outlet and a lip extending into theregister box. A mineral wool layer having a first R value is adjacentthe inside surface of the box and a reflective laminate layer having asecond R value overlies the mineral wool layer.

The insulated HVAC duct component can include an adhesive intermediatethe mineral wool layer and the reflective laminate layer. In oneconstruction, the reflective laminate layer includes a base piece ofreflective laminate material sized to overlap the bottom wall and twoopposing sidewalls of the register box, and side pieces of reflectivelaminate material sized to overlap the other two opposing sidewalls todispose the mineral wool intermediate the respective wall and thereflective laminate layer. The back wall of the register box can alsoinclude a circular inlet and a collar, wherein the base piece ofreflective laminate material includes an aperture for receiving thecollar. The mineral wool layer and the reflective laminate layer can beremovably secured or retained within the register box by the lip.

In another configuration, an insulated register box for a HVAC ductsystem is provided, wherein the register box includes four sidewallsforming four corners, an outer mounting flange, a bottom wall having acircular inlet having a collar, and a top wall having a rectangularoutlet and an inner rib, the inner rib protruding from the top wall andextending into the rectangular box. A first layer of insulation materialhaving a first R value is adjacent inside portions of the sidewalls, theback wall and front wall. The first layer can engage the lip of thefront wall. A second layer of a different insulation material having asecond R value is adjacent outside surface of the sidewalls and backwall. The second layer includes an aperture for receiving the collar ofthe rectangular box.

In yet another configuration, the insulated HVAC duct component includesa transition box at least four sidewalls and one of a top and a bottomwall. The transition box includes a first access port and a secondaccess port, wherein the first access port has a different cross sectionthan the second access port. One of the access ports is spaced from anearest sidewall by less than 2 inches. A first insulation layer islocated along an inside surface of the box and a different secondinsulation layer overlies the first insulation layer to form acomposite. The second different insulation layer has an air impervioussurface. The combined thickness of the first insulation layer and thesecond different insulation layer is less than 2 inches. In a furtherconfiguration, the composite has an R value of at least 8.

A method of insulating a transition box is provided including locating afirst insulation layer along an inside surface of a transition box andoverlying a second air impervious insulation layer on the firstinsulation layer, wherein the second insulation layer is different fromthe first insulation layer and wherein a combined thickness of the firstinsulation layer and the second different insulation layer is less than2 inches. An adhesive layer may be applied intermediate the firstinsulation layer and the second insulation layer. A die cut aperture canbe formed in the first and second insulation layer sized to receive acollar of the transition box. The method can also include locating aperimeter edge of the first and second insulation layers behind a lip ofthe transition box.

Another method of insulating a transition box includes locating a firstinsulation layer having a first R value along an inside surface of atransition box, engaging a perimeter edge of the first insulation layerwith a lip of the transition box, locating a second insulation layerhaving a second R value along an outside surface of a transition box,and folding triangular corner tabs of the second insulation layeragainst an outer surface of the second insulation layer. The triangularcorner tabs can be secured to the transition box and/or the outersurface of the second insulation layer.

In a further configuration, an insulating assembly for an HVAC ductcomponent is provided, wherein the insulating assembly includes areflective laminate body having a base, a first sidewall extending fromthe base and a second sidewall extending from the base, at least one ofthe sidewalls terminating at a free edge; the base and the sidewallsmovable between a first transport configuration wherein a majority ofthe base and a majority of each of the sidewalls are parallel and aninstallation configuration wherein the sidewalls are inclined relativeto the base; and the reflective laminate including an upper reflectivelayer, a bottom reflective layer and a cellular layer intermediate theupper reflective layer and the bottom reflective layer.

In one configuration, a portion of the first sidewall of the insulatingassembly is affixed to a portion of the second sidewall, independent ofthe base. The portion of the first sidewall can be affixed to theportion of the second sidewall by a fastener. It is contemplated thebase, the first sidewall and the second sidewall can be integral.

In a further configuration, the least one of the base, the firstsidewall and the second sidewall includes a line of weakness forremoving a corresponding portion of the at least one of the base, thefirst sidewall and the second sidewall. In an alternative construction,at least one of the base, the first sidewall and the second sidewallincludes a cutout removing a corresponding portion of the at least oneof the base, the first sidewall and the second sidewall.

A layer of mineral wool can be operably located adjacent to one of thefirst sidewall and the second sidewall and the base. The layer ofmineral wool can be parallel to and spaced from one of the firstsidewall and the second sidewall and the base.

The insulating assembly can further include a first polymeric layerbonded to the upper reflective layer, the cellular layer bonded to thefirst polymeric layer, a second polymeric layer bonded to the cellularlayer and the bottom reflective layer bonded to the second polymericlayer.

The insulating assembly can include a fold line between each of thesidewalls and the base and in select configurations, least one of thefold lines can include a score line.

The insulating assembly can further include a third sidewall and afourth sidewall, wherein each of the third and fourth sidewalls includesa collapsing fold line.

The insulating assembly can further include an adhesive on an exposedsurface of one of the base and the sidewalls.

The insulating assembly can cooperatively engage an HVAC component, suchas a transition box, thermally coupled to the reflective laminate body.The reflective laminate body can be located adjacent an inside surfaceof the transition box. Alternatively, the reflective laminate body canbe adjacent an outside surface of the transition box.

The insulating assembly can further include a second reflective laminatebody, wherein the reflective laminate body is adjacent an outsidesurface of the transition box and the second reflective laminate body isadjacent an inside surface of the transition box.

Another method is provided of moving a plurality of sidewalls of areflective laminate insulating assembly from a first transportconfiguration, wherein a majority of a base and a majority of each ofthe plurality of sidewalls are parallel to an installationconfiguration, wherein each of the plurality of sidewalls is inclinedrelative to the base; and disposing the reflective laminate insulatingassembly in the installation configuration about a portion of an HVACduct component to inhibit thermal transfer to or from the HVAC ductcomponent.

In one version, the HVAC duct component can be metallic, and wherein theHVAC duct component can be an HVAC transition box.

The method can also include locating the reflective laminate insulatingassembly adjacent an inside surface of the HVAC duct component.

Similarly, the method can include locating the reflective laminateinsulating assembly adjacent an outside surface of the HVAC ductcomponent.

A method is provided including cutting a planar sheet of reflectivelaminate having an upper reflective layer, a first polymeric layerbonded to the upper reflective layer, a cellular layer bonded to thefirst polymeric layer, a second polymeric layer bonded to the cellularlayer and a bottom reflective layer bonded to the second polymericlayer, to have a base, a first sidewall and a second sidewall; rotatingthe first sidewall about a first bend line to dispose the first sidewallinclined relative to the base; rotating the second sidewall about asecond bend line to dispose the second sidewall inclined relative to thebase; joining a portion of the rotated first sidewall and a portion ofthe rotated second sidewall to form an assembly including the base, thefirst sidewall and the second sidewall; and collapsing the assembly todispose a majority of the first sidewall, a majority of the secondsidewall and a majority of the base in a parallel orientation, whereinat least a portion of one of the first and the second sidewall overliesa portion of the base.

The method can also include cutting a layer of the reflective laminatealong one of the first bend line and the second bend line.

In a further configuration, an insulated HVAC duct component is providedhaving a transition box having at least four sidewalls, a back wall, anda front wall having a first access port, wherein at least a portion ofthe back wall is formed of a duct board; a mineral wool layer having afirst R value, the mineral wool layer adjacent one of an inside surfaceand an outside of the transition box; and a reflective laminate layerhaving a second R value, the reflective laminate layer located at one ofinside the transition box and outside the transition box.

In this configuration, it is contemplated the duct board portion of theback wall includes a second access port fluidly connected to the firstaccess port. It is also understood the mineral wool layer can beintermediate the reflective laminate layer and the back wall.

An additional method is provided including locating a reflectivelaminate about an HVAC component, the HVAC component at least partiallyformed by duct board; and cutting an access port through a portion ofthe duct board and the reflective laminate.

In a further configuration, an insulating assembly is provided, whereinthe assembly has a reflective laminate body including a first pair ofopposing sidewalls extending from a base and a second pair of opposingsidewalls extending from the base with each of the sidewalls terminatingat a free edge. The base and the sidewalls are moveable between a firsttransport position wherein a majority of the base and a majority of thesidewalls are parallel and an installation configuration wherein thesidewalls are perpendicular to the base. The reflective laminateincludes an upper reflective layer, a bottom reflective layer and acellular layer intermediate the upper reflective layer and the bottomreflective layer. It is further contemplated the

BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS

FIG. 1 is a perspective view of a register box without layers ofinsulation.

FIG. 2 is a perspective view of one configuration illustrating a firstinsulation layer located along an inside surface of the register box anda second insulation layer located along an outside surface of theregister box.

FIG. 3 is a perspective view of another configuration showing the firstinsulation layer located along the inside surface of the register boxand the second insulation layer overlying the first insulation layer.

FIG. 4 is an exploded schematic view of the reflective laminate layer.

FIG. 5 is an exploded schematic view of an alternative construction ofthe reflective laminate insulation layer.

FIG. 6 is a cross sectional view of the register box taken generallyalong line 6-6 in FIG. 2 illustrating the first insulation layer locatedalong the inside surface of the register box and the second insulationlayer located along the surface of the register box.

FIG. 7 is a cross sectional view of the register box taken generallyalong line 7-7 in FIG. 3 illustrating the first insulation layer locatedalong the outside surface of the register box and the second insulationlayer overlying the first insulation layer.

FIG. 8 is a perspective view of components of the insulated register boxshowing the first and second insulation layers configured to be insertedinto a register box.

FIG. 9 is a front view of the second insulation layer configured to beinserted into a register box.

FIG. 10 is a perspective view of components of the insulated registerbox showing a configuration of the first and second insulation layersconfigured to be inserted into a register box.

FIG. 11 is a plan view of a cut out of a reflective laminate showing thecomponents prior to folding and bonding to form the insulating assembly.

FIG. 12 is perspective view of the reflective laminate cut out of FIG.11 forming an insulating assembly having a base and sidewalls inclinedrelative to the base.

FIG. 13 is representative cross sectional view of the insulatingassembly of FIG. 12 in a folded or transport configuration.

FIG. 14 in a top plan view of the insulating assembly of FIG. 12 in thefolded or transportation configuration.

DETAILED DESCRIPTION OF THE INVENTION

At the outset, it should be appreciated that the use of the samereference number throughout the several figures designates a like orsimilar element.

Referring to the Figures, an insulated HVAC duct component 10 includesan HVAC transition box 20, a mineral wool layer 50, and a reflectivelaminate layer 60. The HVAC transition box 20 (or transition box)includes fittings, collars, takeoffs, register boxes, boxes, boots,stacks, register boots, stackheads, reducers, elbows, caps and plenums.In one configuration, the transition box 20 includes sidewalls 22, 24,26, 28, a back wall 30, and a front wall 32. The transition box 20further includes an inside surface 34 and an outside surface 36, twoaccess ports 38, 40 having different cross sections. In oneconfiguration, the transition box 20 includes a rectangular access port38 having a rectangular outlet framed by a depending rectangular lip 44that is dimensioned for a snug sliding fit within the rectangularoutlet. The lip 44 is spaced from the adjacent sidewall 22, 24, 26, 28of the transition box 20 by a given fixed distance. Typical spacingbetween the lip 44 and the adjacent sidewall 22, 24, 26, 28 is less thanapproximately one inch, and can be as little as half an inch. Thetransition box 20 can further include a circular access port 40 having acircular inlet and a collar 48.

The rectangular outlet is dimensioned for registration with a diffuser(not illustrated). The circular inlet or access port 40 typically has aninner diameter of 7⅛ inches and forms an opening for receivingpressurized air conducted through a branch conduit of a HVAC system.

A first insulation layer, such as the mineral wool layer 50, having afirst R value and a first thickness is located along an inside surface34 of the transition box 20 as shown in FIGS. 2, 3, 6, and 7. Themineral wool layer 50 has a thickness no greater than the spacingbetween the lip 44 and the adjacent sidewall, and is thus less than oneinch. In most prior constructions, the thickness of the mineral woollayer 50 is between one and three-quarters inch.

In one configuration, the second insulation layer, such as thereflective laminate layer 60, is adjacent the outside surface of thetransition box 20, as shown in FIGS. 2 and 6 and as described in moredetail infra. In another configuration, the second insulation layer 60overlies the first insulation layer, such as the mineral wool layer 50,inside the transition box as shown in FIGS. 3 and 7.

The second insulation layer can be a reflective laminate having an airimpervious surface, a second R value and a second thickness, wherein thesecond thickness is different from the first thickness. In theoverlaying construction of the two layers of insulation, the layers forma composite that can be unbonded or bonded. Thus, a bonding layer 80 maybe included between the first insulation layer 50 and the secondinsulation layer 60, such as the mineral wool layer 50 and thereflective laminate layer 60. In one configuration, the bonding layer 80operably bonds the second insulation layer 60 to the first insulationlayer 50 to form a bonded composite 100. The bonding of the second(reflective) insulation layer 60 and the first (mineral wool) insulationlayer 50 is such that no intermediate gap is formed between the layersof the composite. That is, the second insulation layer 60 is contiguouswith the mineral wool insulation layer (first insulation layer) 50. Thebonding of the second insulation layer 60 and the first insulation layer50 can be formed by a variety of adhesives, such as the water solubleadhesives. In one construction, the adhesive partially penetrates themineral wool fibers and thus forms an integral bond between the firstmineral wool layer 50 and the (second) reflective laminate layer 60.Thus, no additional air gaps are formed by the bonding layer 80 betweenthe mineral wool layer 50 and the reflective laminate layer 60. It isfurther contemplated that the adhesive can be selected such that thebonding layer 80 increases the rigidity of the composite 100. That is,the bonded composite 100 can be self-supporting.

For purposes of this disclosure, the mineral wool layer 50 is a lowdensity nonwoven fiber formed into a layer, wherein the fibers are madefrom minerals or metal oxides, and can be synthetic or natural.Typically, man made mineral fibers (MMMF) generally refer to syntheticmaterials. This includes fiberglass, ceramic fibers and rock wool, alsoknown as stone wool. The mineral wool layer 50 can include organicfibers such as polymeric fibers or inorganic fibers such as rotary glassfibers, textile glass fibers, stonewool (also known as rockwool) or acombination thereof. Mineral fibers, such as glass fibers, have beenfound satisfactory.

The mineral wool layer 50, sometimes referred to as a batt or blanketinsulation generally spans densities in the range of about 0.5-7 lb/ft³(8-112 kg/m³) and preferably about 1-4 lb/ft³ (16-64 kg/m³), and morepreferably 0.3 to 1.5 lb/ft³ (4.8-24 kg/m³). The mineral wool layer 50is usually provided in continuous sheeting that is sometimes cut topreselected lengths, thus forming batts. The thickness of the mineralwool layer 50 is generally proportional to the insulated effectivenessor “R value” of the insulation.

The R value is a commercial unit used to measure the effectiveness ofthermal insulation. That is, the R value is a measure of the capacity ofa material, such as insulation, to impede thermal flow, with increasingvalues indicating a greater capacity. Thermal conductance of a materialis measured, in traditional units, in BTUs of energy conducted timesinches of thickness per hour of time per square foot of area perFahrenheit degree of temperature difference between the two sides of thematerial. The R value of the insulator is defined to be 1 divided by thethermal conductance per inch. This means R value is an abbreviation forthe complex unit combination hr·ft²·° F./Btu. In SI units, an R value of1 equals 0.17611 square meter kelvins per watt (m²·K/W). As defined Rvalue is

${Rvalve} = \frac{\Delta\;{T \cdot A \cdot t}}{HeatLoss}$where Δ is the temperature difference in degrees Fahrenheit, A is thearea in square feet, t is the time in hours, and HeatLoss is the heatloss in BTUs. Typical R values for the mineral wool layer 50 is betweenapproximately 3.1/inch to 4.3/inch thickness of the layer.

In some embodiments, a vapor retarder facing layer 52, which may be acellulosic paper, typically formed from Kraft paper, coated with abituminous adhesive material, such as asphalt, or polymeric film, suchas LDPE (low density polyethylene), is provided on one major surface ofthe mineral wool layer 50. The facing layer and bituminous layertogether form bitumen-coated Kraft paper.

The second or reflective laminate layer 60 is a laminate that includesan upper reflective layer 62, a lower reflective layer 66 and anintermediate cellular layer 64.

In one construction, the cellular layer 64 is comprised of a multitudeof closed cells. While the cellular layer 64 can be formed of opencells, as the closed cells provide enhanced resistance to thermal flow,the closed cell structure has been found satisfactory. The closed cellsof the cellular layer 62 can be formed from a foamed polymer includingthermoplastics, thermosets or thermoplastic elastomers, as is wellknown. Alternatively, the cellular layer 62 can be formed of a multitudeof sealed pockets, each retaining a volume of air or other gas. Thecellular layer 62 can have any of a variety of thickness, such as butnot limited to 3/16 inch to one half inch.

The pockets of the cellular layer 64 can be in form of a layer ofdiscrete bubbles, or multiple layers of bubbles as defined by a polymer.The discrete bubbles can be as small as 1/10 inch in diameter, to aslarge as an inch or more. In addition, the volume of gas retained withinthe bubble can be controlled to provide differing degrees of thermalprotection or control the resulting thickness of the cellular layer.That is, the bubble may be under a positive pressure, rather than merelyretaining a volume of gas.

In one configuration, the reflective laminate 60 can include at leastfive layers—the upper and lower reflective layers 62, 66, a polymerlayer 68, 70 adjacent each reflective layer 62, 66, wherein each polymerlayer is selected to increase strength of the laminate and the cellularlayer 64 intermediate the two polymer layers. Polyethylene has beenfound a satisfactory polymer for the polymer layer. Thus, for example,each reflective layer 62, 66 can be bonded to a polyethylene layer 68,70, wherein the polyethylene layers sandwich the cellular layer 64therebetween. Alternatively, the reflective laminate 60 can be formedwith three layers—the upper reflective layer, the lower reflective layerand the intermediate cellular layer, wherein the upper and lower layerssandwich the cellular layer and a bonding such as adhesive or ultrasonicwelding joins the layers together.

In a further construction, the reflective laminate (or second insulationlayer 60) can include two cellular layers 64, 74, wherein the twocellular layers are connected by an intermediate polymer layer 72, suchas a polyethylene layer. Thus, the second insulation layer 60 can havethe five layer construction including (i) the upper reflective layer 62,(ii) the polymeric layer 68, (iii) the cellular layer 64, (iv) thepolymer layer 70, and (v) the lower reflective layer 66, or the sevenlayer construction including (i) the upper reflective layer 62, (ii) thepolymer layer 68, (iii) the cellular layer 64, (iv) the polymer layer72, (v) the cellular layer 74, (vi) the polymer layer 70, and (vii) thelower reflective layer 66.

A satisfactory reflective laminate 60, as the second insulation layer,is a foil/bubble reflective insulation marketed by Reflectix, Inc ofMarkleville Ind. under the mark Reflectix®, including either the singlebubble or double bubble product.

In one construction, the second insulation layer 60 is the Reflectix®double bubble product having a nominal thickness of 5/16 inch and an Rvalue of approximately 4.2. In this construction, the mineral wool layer50 has a thickness of one inch and an R value of approximately 4 to 4.2,and the R value of the resulting composite 100 is approximately 8, andhas a thickness of approximately 1 5/16 inch. Thus, the two layers ofinsulation are of different materials and different thickness.

In contrast, as set forth by Reflectix® publications, if the Reflectix®product (second insulation layer 60) is simply doubled (that is twoReflectix® reflective laminate 60 layers are directly bonded together),the resulting construction has an R value of approximately 5.3, ratherthan the expected 8.4 of the combined R values. Thus, merely doublingthe reflective laminate layer 60 does not provide the desired R value.Further, pursuant to Reflectix® company literature, a ¾ inch air spaceis recommended on each side of the second insulation layer 60. Suchspacing thus requires a 1 13/16 wide gap thereby limiting installationof the composite 100. Alternatively, if the mineral wool layer 50 wereused to obtain an R value of 8, the mineral wool layer 50 would have athickness of approximately two inches.

The composite of the first insulation layer (the mineral wool layer) 50,and the second insulation layer (the reflective laminate layer) 60, canbe constructed such that the R value of the composite 100 is greaterthan, less than or equal to the R value of the mineral wool layer 50.Further, the R value of the composite 100 is at least 80% of the sum ofthe first R value and the second R value. In certain constructions, theR value of the composite is at least 90% and can be 95% of the sum ofthe R value for the reflective laminate and the R value of the mineralwool layer. For example, as the reflective laminate layer as the secondinsulation layer 60 has an R value of approximately 4.2 and the firstinsulation layer as the mineral wool layer 50 has an R value ofapproximately 4.2, the composite 100 has an R value of at leastapproximately 80% of an 8.4 R value and in selected constructions an Rvalue of at least 90% of the added R value of the second insulationlayer (the reflective laminate layer) 60 and the first insulation layer(the mineral wool insulation layer) 50.

The composite 100 can have a thickness that is less than twice themineral wool layer 50, yet have an R value that is substantially equalto twice the R value of the mineral wool layer 50. For example, thereflective laminate can have an R value of 4 with a 5/16 inch thicknessand the mineral wool layer can have an R value of 4 with a one inchthickness, the resulting composite 100 (bonded or unbonded) having an Rvalue of 8 and a thickness of 1 5/16 inch. As two directly bondedreflective laminates, (if bonded together without intermediate air gap)exhibit an R value of approximately 5.3 (4.2+1.1), the composite 100 hasan R value that is greater than the R value of bonded reflectivelaminate layers.

It is understood the composite 100 can be formed with variety ofthicknesses of the mineral wool layer 50. For example, if the mineralwool layer 50 is sized to provide an R value of 6, then the resultingcomposite 100 has an R value of approximately 10.

Conversely, the second insulation layer 60 can be used in combinationwith a relatively thin mineral wool layer 50, such as one having a Rvalue of 2 ( 7/16 inch thick). Thus the R value 4 of the secondinsulation layer 60 provides a composite 100 having an R value ofapproximately 6 with a thickness of ¾ inch in contrast to a thickness of1.5 inches in prior constructions.

Although the first insulation layer is set forth as the mineral woollayer and the second insulation layer is set forth as the reflectivelaminate layer, it is understood the first insulation layer and thesecond reflective laminate layer can be any two different insulationmaterials, with or without an air gap, wherein the air gap is within oneof the layers or formed between the two layers.

That is, the composite 100 is formed of two different insulationmaterials, wherein one or each of the insulation materials can be asingle material or layer or laminate.

As the present construction provides for comparable R values at reducedthickness (as compared to prior constructions) the HVAC components to beinsulated by the present construction can be of standard or reducedsize, thereby reducing material costs. Further, reduced sizing allowsinstallation in previously inaccessible locations.

It is contemplated that the insulated HVAC duct component 10 can be anytype of duct component used in an HVAC system where insulation isdesired. Without limiting the scope of disclosure, the first and secondinsulation layers 50, 60 are set forth in terms of operable connectionwith the ducts 10 in the configuration of a transition box 20, includingbut not limited to a register box, plenum box, ceiling box, registerboot, stack boot, box, boot, stack, and stackhead. Register boxes 20 areemployed to distribute a pressurized air flow from a main or trunk ductto a room interface. As the register box 20 is located at the exposureto a room, the register box is typically located in areas of limitedspacing. That is, the register box 20 typically must conform to a givensize limitation.

Referring to FIG. 1, the register or air distribution box 20 isconstructed of sheet-metal, such as galvanized 30-gauge steel panelsforming sidewalls 22, 24, 26, 28, the back wall 30, front wall 32, andan outer flange 18. In one configuration, the sidewalls 22, 24, 26, 28are constructed from a single blank of galvanized sheet metal steel.Opposing sidewalls 22, 26 and 24, 28 and the back wall 30 include flangeportions that are folded over the sidewalls and are staked together toform a mechanically stable unit. When assembled and connected together,the sidewalls 22, 24, 26, 28, the front wall 32 and the back wall 30provide boundaries for an air distribution chamber of the register box20. For the exemplary embodiment shown in FIG. 1, the register box 20dimensions are 14 inches by 3½ inches by 8 inches. The front wall 32 mayalso include vents 16 for venting the insulation layers 50 and/or 60.

Although the HVAC component is described in terms of a metalconstruction, it is understood that a variety of materials can be usedto for the component, such as laminates, plastics and alloys.

Thermal insulation, in the form of the composite 100 (bonded orunbonded) or the mineral wool layer 50 on one side of the box and thereflective laminate layer on the other side, is added to the internalsurfaces of the sidewalls of the register box to prevent heat transferand for noise reduction purposes. However, as the footprint of theregister box 20 is limited and the relative size of the air passagewaysmust be maintained, the available space for insulation is restricted.

The present insulation layers 50, 60 can be disposed within theavailable standard spacing in an existing register box 20 as shown inFIGS. 3 and 7, yet provide enhanced R value such as R8.

The first and second insulation layers 50, 60 can be disposed within theregister box 20 so that the exposed surface of the second insulationlayer (the reflective laminate) 60 contacts the air flow through theregister box 20. Thus, the reflective layer of the reflective laminatedefines the surface of insulation that is exposed to the air flowthrough the HVAC duct and reduces the entrainment of the underlyingmineral wool layer 50 in the air flow. This improves indoor air quality.In this configuration, as shown in FIG. 8, the insulation layers 50, 60includes a base piece 90 sized to overlap the back wall 30 of theregister box 20, two pieces 92, 94 sized to overlap two opposingsidewalls 22, 26 and two pieces 96, 98 sized to overlap two opposingsidewalls 24, 28 of the register box 20. The base piece 90 includes anaperture 104 for receiving the collar 48 of the register box 20. For theexemplary embodiment shown in FIG. 1, wherein the register box 20dimensions are 14 inches by 3½ inches by 8 inches, the base piece 90sized to overlap the back wall is about 12 inches by 8 inches, two ofthe sidewall pieces 92, 94 are about 12 by 3½ inches and two of thesidewall pieces 96, 98 are about 8 inches by 3½ inches. In analternative configuration, as shown in FIG. 9, the first and secondinsulation layers 50, 60 include a base piece 91 sized to overlap theback wall 30 and the two opposing sidewalls 22, 26 of the register box20 and side pieces 92, 94 sized to overlap the other two opposingsidewalls 24, 28. That is, the base piece 91 is about 15 inches by 12inches and the side pieces 92, 94 are each about 8 inches by 3½ inches.

As shown in FIG. 10, the reflective laminate 60 may include a singlepiece blank of reflective laminate 60 having four base forming foldlines 112, 114, 116, 118, a base 119, and four side flaps (sidewalls)122, 124, 126, 128. The four side flaps 120, 122, 124, 126 are typicallyformed by removing corner portions of the reflective laminate andbending the flaps 122, 124, 126, 128 along the base forming fold lines112, 114, 116, 118. The second insulation layer 60 typically includes adie-cut aperture 106 for receiving the collar 48, although it should beappreciated by those having ordinary skill in the art that other methodsmay be used to form the aperture in the second insulation layer. For theexemplary embodiment shown in FIG. 1, wherein the transition box 20dimensions are 14 inches by 3½ inches by 8 inches, the reflectivelaminate layer 60 has the following dimensions: the base measures about12 inches by 8 inches and each flap measures about 8 inches by 3½inches.

Thus, a self-supporting reflective laminate 60 forming an insulatingassembly 160 is formed by folding each of the side flaps (sidewalls)120, 122, 124 and 126 about the respective fold line and joining theabutting edges or corresponding portions of the sidewalls to form (orretain) the sidewalls generally perpendicular to the base 119.Fasteners, including but not limited to tape, staples, stitching,bonding, ultrasonic welding or adhesives can be used affix abutting sideflaps to each other. Fasteners includes mechanical fasteners such asstaples, rivets, barbs, darts, clips.

In a further configuration, the sidewalls 120, 122, 124 and 126 caninclude mating tabs and slots, wherein the tab or tabs of one sidewallare received into corresponding slots 129 on an adjacent sidewall toengage the walls and dispose the laminate in a self-supportingorientation, such as the insulating assembly 160. In this configuration,no mechanical fasteners are required to retain the insulating assembly160 in the operable orientation. That is, a substantially selfsupporting orientation able to retain the assembly in the operableconfiguration.

The fold lines, such as fold lines 112, 114, 116, 118, can include aline of weakness such as a score, perforation or even stressed sectionof material. The line of weakness can be used to promote folding of therespective wall or relative to the base. As set forth herein, theremaining material along the fold line forms a hinge about which therespective components of the insulating assembly 160 can pivot fortransition from a storage/shipping configuration to use or installationconfiguration.

It is further understood, the line of weakness can be sufficient depthor fracture of material of the reflective laminate 60 to permit aseparation of the material along the line. That is, the line of weaknesscan render the laminate 60 sufficiently frangible that the material canbe separated into distinct pieces. This allows for an installer toremove an area of material from the laminate 60 (or assembly 160), suchas a vent hole, during installation, without requiring the use ofseparate tools or knives. That is, the installer merely applies atearing or rendering force along the lines of weakness and the portionsof the reflective laminate 60 (or assembly 160) are separated.

Referring to FIGS. 10-13, the reflective laminate layer 60 can be thusformed into the self-supporting reflective laminate body or insulatingassembly 160 having the base 119 and the four extending sidewalls 122,124, 126 and 128, wherein the sidewalls are at least substantiallyperpendicular to the base. Longer sidewalls 122, 126 can each includetwo collapsing fold lines 127. The collapsing fold line 127 extends fromthe junction of the base 119, the longer opposing sidewall 122, 126 andone of the shorter sidewalls 124, 128 at an approximate 45 degree angleto the free edge of the longer sidewall. The collapsing fold lines 127form triangular portions in the longer of the sidewalls, such that asthe short sidewalls 124, 128 are folded about fold lines 116, 112respectively, toward each other, the longer sidewalls 122, 126 rotatetowards each other about respective fold lines 114, 118 and thetriangular portions fold about the adjacent collapsing fold line 127until the base 119, the shorter sidewalls 124, 128, the triangularportions and the remaining portions of the longer sidewalls 122, 126 areparallel as seen in FIG. 13. The resulting collapsed structure has athickness of 4 layers of the reflective laminate 60.

In addition, as seen in FIG. 11 the sidewalls 122 and 126 can includeprojecting tabs 122′, 122″ and 126′ and 126″ respectively, wherein theprojecting tabs are folded to overlay a portion of the adjacent sidewalland fastened to that sidewall, such as by staples, adhesives, stitchingor bonding to form the self-supporting assembly.

As set forth above, the tabs 122′, 122″ and 126′ and 126″ can beconfigured to be received in corresponding slots 129 (shown in FIG. 11)in the adjacent sidewall to operably engage the sidewalls, such as inthe open orientation.

As in the alternative construction, the longer sidewalls 122, 126 caninclude collapsing fold lines 127 and the joined sidewalls 124, 128 canbe folded about the respective fold lines and the respective sidewallsfolded about the collapsing fold lines such that a majority of thesidewalls are parallel to a majority of the base 119 and the sidewallsgenerally overlie the base.

Thus, the insulating assembly 160 can be compactly configured forefficient shipment and storage. In the shipping or storageconfiguration, the sidewalls or flaps 120, 122, 124 and 126 or portionsare folded about the respective fold lines 112, 114, 116, 118 so thatthe sidewalls are substantially parallel to each other as well as thebase 119. Further, in one configuration, the folded sidewalls 120, 122,124 and 126 are within the footprint (or periphery) of the base 119. Inresponse to customer need for an existing HVAC duct component to haveincrease R value or a retailer wishing to offer a line of suchcomponents having increased R value, the insulating assembly 160 can beunfolded to assume the self-supporting configuration, wherein thesidewalls 122, 124, 126, 128 are generally perpendicular to the base119.

To transition the insulating assembly 160 from the transportconfiguration to the installation configuration, the sidewalls 122, 124,126, 128 rotate about the respective fold lines until the sidewalls areperpendicular to the base 119, and the assembly is self-supporting. Theopened insulating assembly 160 can then be slid over the outside surfaceof the HVAC component or tucked within the HVAC component, depending onthe intended operation.

Thus, a collapsible insulating assembly 160 for HVAC ductwork isprovided, wherein the assembly can be disposed in a transportconfiguration, wherein the walls or portions are folded about fold linesto be at least substantially parallel with each other and the base 119and an operative configuration, wherein the opened insulating componentencompasses a portion or is encompassed by a portion of a HVAC ductwork.

It is contemplated that one layer of the reflective laminate 60 can bescored or actually cut along the desired fold lines 112, 114, 116, 118,such as each fold line or alternating fold lines, thereby reducing theeffective radius of curvature of the bend. In one configuration, the cut(or score) is formed along the outside surface of the respective foldline 112, 114, 116, 118, that is the surface of the laminateexperiencing the greater radius of curvature. It is contemplated thefold lines 112, 114, 116, 118 for one, a pair or all the sidewalls canbe scored to provide the reduced bending deformation and assist indisposing the insulating assembly 160 in the transport configuration.Thus, the remaining thickness of the reflective laminate 60 forms ahinge about which the sidewall can pivot relative to the base 119.

To incorporate both insulation layers 50, 60 into the register box 20,the mineral wool (layer) 50 is located along the inside surface 34 ofthe register box 20. The perimeter edges of the mineral wool layer 50engage the lip 44 of the register box 20 to secure the mineral woollayer 50 in place. The second insulation layer 60 (the reflectivelaminate layer) is then placed along the top (exposed) surface of themineral wool, wherein a perimeter edge of the second insulation layer 60engages the lip 44 of the register box 20 securing the second insulationlayer in place. In one configuration, an adhesive as described supra isplaced between the mineral wool layer 50 and the reflective laminatelayer 60 to provide the bonded composite 100. Alternatively, the secondinsulation layer can be located against the mineral wool, and retainedin place by a slight compressive force from the lip 44 and the adjacentsidewall. The combined thickness of the mineral wool layer 50 and thereflective laminate layer 60 (and hence composite 100) is less than twoinches, and in selected configurations, less than approximately 1 inch,depending on the specific configuration of the transition box.

Thus, as the second insulation layer 60 is in contact with the passingair flow in the register box 20, there is no exposed mineral wool to theair flow through the register box 20. Therefore, less mineral wool isentrained in the passing air flow, and indoor air quality is improved.

In another configuration, the mineral wool layer 50 is disposed withinthe existing register box 20 and the second insulation layer 60 (thereflective laminate) is disposed on the outside of the register box 20as shown in FIGS. 2 and 6. The mineral wool layer 50 can be insertedinto the register box 20, for example, as described in supra. For theexemplary embodiment shown in FIG. 1, the second insulation layer 60overlies the outside surface 36 of the sidewalls 22, 24, 26, 28 and backwall 30 of the register box 20. The second insulation layer 60 furtherincludes triangular tabs 138 located at each corner of the sidewalls 22,24, 26, 28, wherein each triangular tab 138 lies flat along a portion ofthe second insulation layer 60. In one configuration, two triangulartabs 138 overlie one sidewall 22 and two triangular tabs overlie theopposing sidewall 26. The triangular tabs 138 are secured to theregister box 20 by fasteners 140. Fasteners 140 can include, but are notlimited to, pins, adhesives, screws, staples and nails. In anotherconfiguration, the triangular tabs 138 are secured to the secondinsulation layer 60. For example, triangular tabs 138 can be fastenedand/or adhered to the surface of the second insulation layer 60. In afurther configuration, selected sidewalls can include an integral tabsized to overlie a portion of the an adjacent sidewall (in the operableconfiguration) wherein the tab is secured to the adjacent sidewall byany of the previously listed fasteners.

In both configurations, the enhanced insulation capacity of the presentinvention reduces energy costs as well as increases useful life of theregister box.

Thus, the reflective laminate body 160 can be sized fit within thetransition box 20 or slide over the outside surface of the transitionbox. For either configuration, the sizing of the reflective laminatebody 160 can be selected to provide a friction fit or retention, orcooperate with fasteners including mechanical fasteners or adhesives,such as adhesive layer 170.

In a further configuration, the insulating assembly 160 is shipped inthe shipping configuration, with the base 119 and sidewalls 120, 122,124 and 126 being substantially parallel. In use, the insulatingassembly 160 is transitioned to the installation configuration andengaged with the HVAC component, such as the transition box 20. Theinsulating assembly 160 can be engaged directly to the transition box 20on either the inside surface 34, the outside surface 36 or if twoinsulating assemblies are employed, both the inside surface and theoutside surface.

The resulting construction includes the transition box 20 having thereflective laminate 60 insulating assembly 160 in a thermal barrierengagement relative to the inside surface 34, the outside surface 36 orboth the inside surface and the outside surface of the transition box20—wherein additional insulation layers of different material can belocated intermediate the insulating component and the transition box orthe additional insulation layers can be engaged to locate the insulatingassembly intermediate the respective surface of the transition box andthe additional insulation layer.

The use of the prefabricated insulating assembly 160 gives the installerthe flexibility to use one or two of the assemblies with or withoutadditional insulating layers, such as the batten or wool. The insulatingassemblies 160 can be located relative to the transition box 20 with oneon the inside surface, one on the outside surface or both on either theinside surface or the outside surface of the transition box—with orwithout additional layers of different insulation, wherein theadditional layers of insulation can be exterior to the insulatingassembly 160 or intermediate the insulating assembly and the transitionbox.

A retailer could inventory a transition box 20 of a given dimensionhaving the layer of mineral wool on the inside surface providing an Rvalue of approximately 4. By virtue of the present disclosure, thereflective laminate assembly 160 can be selectively located on theinside or the outside of the transition box, thereby increasing theeffective R value of the transition box to 6, or 8 or more, depending onthe thickness of the reflective laminate (the reflective laminateassembly).

In an alternative configuration, at least the back wall 30 of thetransition box 20 can be formed of duct board. Satisfactory duct boardsinclude those by Johns Manville, Owens Corning as well as CertainTeedSaint-Gobain. The duct board is able to be readily cut by commerciallyavailable knives. Thus, the transition box 20 can be formed with only asingle access port, the large access port 38, wherein the transition boxincludes the insulation and reflective laminate 60 as in theconfigurations set forth above. It is understood, the insulatingassembly 160 can be constructed to be without apertures (other than themain opening of the box), such that the installer can form the necessaryspecific ports for installation. Also, the insulating assembly 160 caninclude the lines of weakness for preferential separation of portions ofthe assembly to match the corresponding transition box 20.

The installer on-site then uses the commercially available knife andforms an access port in the back wall 30 as dictated by the on-siteconstruction. The formed access port extends though the insulatingmaterial as well as the duct board. Thus, the installer can form any ofa variety of access ports such as a circular access port, wherein aseparate tab collar, as known in the art, can be used to interconnectthe transition box to the on-site duct. This configuration of thetransition box 20 including a duct board wall (or portion of the wall),provides for the installer on-site to customize the transition box,without sacrificing the thermal performance of the transition box.

It is contemplated that one, two or more walls of the transition box canbe partly or completely formed of the duct board. In one configuration,the entire transition box is formed of duct board, thereby allowing theon-site installer to fully customize the transition box to the on-siteconstruction. As the insulating assembly 160 can be assume an openconfiguration corresponding to the transition box 20, the installer cansimultaneously modify the transition box and the insulating assembly onsite to accommodate unique (or even standard) configurations.

Thus, by locating the insulating assembly 160 (without having anypreformed apertures or ports in the base or sidewalls) about the HVACcomponent, such as the transition box 20, the installer can then customcut the duct board and the adjacent portion of the insulating assemblyto form a matching construction of the HVAC component and the insulatingassembly. That is, by cutting the duct board of the HVAC component andthe insulating assembly 160 substantially simultaneously (while they areoperably aligned), the resulting fit between the HVAC component and theinsulating assembly is ensured.

The insulating assembly 160 can be used in conjunction with any otherinsulating material, wherein the ordering (layering) of the materialsrelative to the environmental temperature gradient can be in any order.

In a further configuration, as seen in FIGS. 11, 12 and 13, thereflective laminate 60 and insulating assembly 160 can include a layerof adhesive 170. The adhesive layer 170 can be substantially uniformacross the area of the reflective laminate 60 or the insulating assembly160. Alternatively, the adhesive layer 170 can be applied in a patterneither to reduce the amount of adhesive used or in a predeterminedpattern to accomplish a function such as bonding to a portion of thetransition box 20 or another layer of insulation upon engagement.

The adhesive layer 170 is shown in predetermined areas on the flaps inFIG. 11. It is understood the predetermined areas can be on any portionof the assembly 160 for either retaining the assembly in the operatingorientation or bonding the assembly to the HVAC component. For example,the adhesive layer 170 can be applied on a majority of an inside oroutside surface of the insulating assembly 160, such that upon operableinstallation of the assembly with the HVAC component, the adhesive layer(if on the inside of the assembly) retains the assembly relative to theoutside of the HVAC component or additional insulating layer, ifpresent, on the outside of the HVAC component and the adhesive layer (ifon the outside of the assembly) retains the assembly relative to theinside of the HVAC component, or additional insulating layer, ifpresent, on the inside of the HVAC component.

The adhesive can be a tape or contact adhesive with or without aremovable backing layer 172. In use, the installer configures thereflective laminate 60 or insulating assembly 160 in the operableconfiguration (removes the backing layer 172, if employed) and pressesthe reflective laminate or insulating assembly into engagement, whereinthe adhesive retains the laminate or assembly is operably retained. Asseen in FIG. 12, a representative sidewall 128 includes the adhesivelayer 170. Referring to FIG. 13, the adhesive layer 170 is shown (inexaggerated thickness) on sidewalls 124 and 128, wherein the backinglayer 172 is shown in a partially peeled configuration relative tosidewall 124.

The adhesive can be a tape such as 3M Double Coated Tapes or contactadhesive as known in the art, such as 3M Hi-Strength spray adhesive orFastbond™ adhesive as well as Scotch-Weld™ adhesive.

While the invention has been described in connection with a particularembodiment, it is not intended to limit the scope of the invention tothe particular form set forth, but on the contrary, it is intended tocover such alternatives, modifications, and equivalents as may beincluded within the spirit and scope of the invention as defined by theappended claims.

The invention claimed is:
 1. A method of insulating a transition boxcomprising: (a) transitioning at least one of a first thermal insulationlayer and an air impervious second thermal insulation layer from atransport configuration to an installation configuration, wherein theair impervious second thermal insulation layer includes an integral baseand a sidewall, the base and the sidewall being parallel in thetransport configuration and inclined in the installation configurationand at least one of the base and the sidewall including an apertureconfigured to receive a portion of the transition box therethrough; (b)locating the first thermal insulation layer along one of an insidesurface and an outside surface of a transition box; and (c) overlyingthe first thermal insulation layer with the air impervious secondthermal insulation layer, wherein the air impervious second thermalinsulation layer is different from the first thermal insulation layerand the air impervious second thermal insulation layer includes an upperreflective layer, a bottom reflective layer, and a cellular layer, thecellular layer being intermediate the upper reflective layer and thebottom reflective layer, and the cellular layer having a plurality ofclosed cells that provide resistance to thermal flow, wherein the airimpervious second thermal insulation layer has a nominal thickness. 2.The method of insulating a transition box of claim 1, wherein a combinedthickness of the first thermal insulation layer and the second thermalinsulation layer is less than 2 inches.
 3. The method of insulating atransition box of claim 1, further comprising applying an adhesiveintermediate the first thermal insulation layer and the second thermalinsulation layer.
 4. The method of insulating a transition box of claim1, further comprising die cutting an aperture in the first and secondthermal insulation layer sized to receive a collar of the transitionbox.
 5. The method of insulating a transition box of claim 1, furthercomprising locating a perimeter edge of the first and second thermalinsulation layers behind a lip of the transition box.
 6. The method ofinsulating a transition box of claim 1, wherein first thermal insulationlayer is located along the inside surface of the transition box.
 7. Themethod of insulating a transition box of claim 1, wherein first thermalinsulation layer is mineral wool.
 8. The method of insulating atransition box of claim 1, wherein the first thermal insulation layer islocated along the outside surface of the transition box.